Manufacturing · Sensor Manufacturer Management Software

One connected system for element lots, calibration runs, certificates and field returns.

Sensor families, variant codes, element lots, bench builds, calibration runs, master gauges, certificates, OEM orders and drift returns share one record. Each unit keeps its readings, its compensation coefficients and the master that calibrated it. A returned transmitter opens to the element lot, the potting batch and the chamber run behind it. Nothing is retyped.

Share your requirements

Families, variant rules, span limits and calibration points entered as your product engineers define them
Element lots, serial history, master gauge list and open OEM orders migrated from your lab workbooks
Changes to calibration forms and certificate layouts made by GullySystem staff on request

This system holds sensor families with released variant codes, element lots, assembly and calibration records, a master gauge register, certificates and field returns. Each serial number links to its element lot, readings and coefficients. A certificate prints from stored readings. Drift complaints group by element lot, potting batch and housing supplier.

Where it breaks today

What goes wrong before the software.

Readings stay on the calibration station

Each run writes a CSV to the local drive of the calibration station, so when the PC is replaced or the engineer leaves, an old certificate cannot be reproduced. A customer audit then asks for exactly that.

Master instruments lapse unnoticed

A reference thermometer or pressure gauge has its own due date, and the list sits with one person. Units are calibrated against an expired master. The whole batch must be redone.

Element lots are mixed on the bench

Elements from two supplier lots are used in the same week, and units are built, potted, boxed and shipped without any record of which lot went into which housing. Recalls become guesswork.

Variant codes outgrow the sales sheet

Ranges, outputs, process threads and cable lengths combine into hundreds of model codes, and a quotation can name one that has never been built. Engineering finds out after the order.

Coefficients are written, then forgotten

Compensation values are programmed into the unit’s memory at calibration, but if it returns with drift, the coefficients originally written are nowhere on file for comparison. The study starts blind.

Returns are studied one at a time

A returned sensor is bench-tested and a free-text note is written, so patterns by element lot, potting batch or cable supplier never appear. Each case looks like a one-off.

How it runs

How the work flows through it, step by step.

1
Enquiry and variant check
The buyer names a range, an output such as 4 to 20 mA and a process thread, then the model code is checked against released variants before quoting. An unbuilt combination stops here.
2
Element receipt and incoming test
Sensing elements arrive in lots with supplier readings, incoming samples are measured against the datasheet, and a lot that fails is held. Nothing from it reaches the bench.
3
Assembly and sealing
Elements are bonded to boards, housed in stainless bodies and then potted or laser welded, and operators log the adhesive or potting compound batch used with each build. Every build names its bench.
4
Calibration
Units go into a temperature chamber or onto a pressure controller, readings at each point are stored, coefficients are written, and the master instrument is recorded against the run. Failures go to rework.
5
Final test and certificate
Accuracy, hysteresis and ingress checks are done and attached to the serial number, then a certificate prints from the stored readings. A reprint matches the original.
6
Shipment and field feedback
Units ship with labels and certificates, and later returns and drift reports are booked against the serial number and grouped by cause for the design team. Patterns show up.

Modules

What is inside.

Every module can be switched on, left out or changed to match how your team already works.

Families and variant rules

Hold every family with its valid ranges, outputs, connections and cable lengths, so a custom OEM variant is released once by engineering and then quoted freely. Quotes stay inside released codes.

Sensing element lots

Receive elements by lot, record incoming readings against the datasheet limits and hold failing lots, so each build shows the exact lots it consumed. Lookups run both ways.

Bills of materials and builds

List elements, boards, housings, seals, potting compound and cable for each model, and let build orders issue the parts while recording the operator and the bench. Parts issue against the bill.

Calibration runs and coefficients

Store readings at every calibration point, the coefficients written to the unit and the chamber or pressure controller used, and route units outside limits to rework or scrap. Each run keeps its record.

Reference instrument register

List master gauges, reference thermometers and dead-weight testers with their certificates and due dates, and block expired instruments from new calibrations. No one keeps it in their head.

Final test and ingress checks

Record accuracy, hysteresis, insulation resistance and IP ingress results per unit with the tester’s name and date, and hold a failed unit back from the packing bench. Failures stay on the bench.

Certificates and labels

Print certificates from stored readings, with labels carrying model code, range and serial number, so a reprint three years later matches the original. Each reprint is logged by customer.

Field returns and drift study

Book returns by serial number, record the coded finding, and compare the stored coefficients against the new bench reading, so faults group by lot, batch and supplier. Drift becomes a pattern.

OEM orders and schedules

Take orders against model codes with delivery dates and customer-specific labelling, and let each order line show whether its units are in assembly, calibration or packing. Orders follow released codes.

Purchasing and supplier records

Compare quotes for elements, housings and connectors, and keep supplier audit notes and certificates of conformity on the same supplier record. Audit notes stay beside the price.

Invoices and export

Raise invoices with currency and tax settings for each country, then export the entries to your accounting software as a spreadsheet file. Columns are agreed up front.

Solutions inside

The business modules it is built from.

Each one is also available on its own, or inside a system built for you.

Product Management
Every family lists its released spans, output signals and process threads, so a quotation can name only a code that engineering has built.
Batch and Serial Tracking
Elements are received by lot with incoming readings, and every finished sensor records its lot, which lets a drift study start from the right batch.
Bill of Materials
Elements, boards, housings, seals and potting compound form one bill per model, and each build order draws its parts against that bill.
Quality Control
Accuracy, hysteresis, insulation and IP ingress results are recorded per unit, and a failed sensor is held back from the packing bench.
Fixed Asset Register
Master gauges, reference thermometers and dead-weight testers carry their certificates and due dates, and an expired instrument is refused for any new calibration run.
Ticket Management
A returned sensor becomes a numbered case with a coded finding, so drift and ingress failures can be grouped by element lot and cable supplier.
Order Management
Orders are taken against model codes with dated releases, and every line shows whether its units sit in assembly, calibration or the packing bench.
Vendor Management
Element, housing and connector suppliers hold audit notes, conformity certificates and quoted rates on one record, and the buyer compares them at purchase time.

Services

How we would put it in.

Setup, data migration, integrations and anything built on top.

Who uses it

One system, each person sees their part.

For owners and managing directors

See orders due, units in calibration, master gauges overdue and returns by cause, all without ringing the lab. One page covers it.

For design and product engineers

Release variants, study drift against element lots and potting batches, and revise the coefficient rules for a family. Rules are yours to set.

For calibration technicians

Run the chamber, save readings, write coefficients and see which reference instrument to use for the range in hand. The screen lists valid masters only.

For quality and the lab manager

Keep the instrument register current, sign certificates and review returns by element lot and housing supplier. Expiry dates stay visible.

For sales and customer support

Quote only released variants and look up a serial number to answer a customer’s query about its range, certificate or ship date. The lab is not disturbed.

Reports

The numbers the owner asks for.

Units calibrated by day, station and technician
Master gauges and thermometers due or overdue
Element lots with failing incoming readings
Hysteresis and ingress failures by model and cause
Field returns by element lot, potting batch and housing supplier
OEM orders open, with stage reached
Certificate reprints requested, by customer

Good fit

Who this is built for.

Makers of pressure transmitters, pressure switches and load cells
Manufacturers of temperature sensors, RTDs and thermocouple assemblies
Producers of inductive proximity, ultrasonic level and flow sensors
Companies building gas and humidity sensing modules
Makers of embedded sensor modules for OEM customers
Firms that calibrate every unit they ship

Honest answer

When it is not the right choice.

A distributor that resells sensors made elsewhere can work with simple stock and billing records.
Makers of general control gear will find Industrial Electronics Manufacturer Management Software closer.

Made to fit

Adapted to your business before it goes live.

You are not handed a login and left to it. The product is set up around your records, your people and the tools you already use.

Variant rules

Ranges, outputs, process threads, cable lengths and the combinations that are released are entered with your product engineers, family by family. Unbuilt ones stay blocked.

Calibration points and limits

Points per range, soak times, accuracy limits and coefficient rules for each family are agreed with your lab staff and tried on a sample unit first. Nothing goes live untried.

Certificate layout

The certificate carries the wording, units, tolerance table and signatures your customers and your own quality staff expect. Layouts are drawn up with a real sample.

Existing records migrated

Lot receipts, serial history, customer files and the list of master gauges are keyed in from the workbooks your lab keeps now, then checked against a few old certificates.

Works alongside

Calibration station files
Barcode and label printers
Email
SMS or WhatsApp
Accounting export

Common questions

Questions owners ask before a demo.

Does it store the actual readings behind a certificate?

Yes. The readings at each calibration point, the coefficients written and the master instrument used are kept per serial number. A certificate is a print of that stored data, so nothing is typed twice.

What stops a calibration using an expired master gauge?

The register records each reference instrument with its own due date. A calibration cannot be saved against an instrument past that date, and the technician is shown the valid alternatives for that range.

How are element lots linked to finished sensors?

Build orders record the element lot consumed. Looking up a serial number shows its lot, and looking up a lot lists every serial number that carries it, even those already shipped to an OEM.

Can OEM buyers have private variants?

Yes. A custom range, label or cable length can be released as a variant for one buyer. It appears only in that buyer’s quotations, never in the general catalogue.

How do returns help the design team?

Findings are recorded as coded faults, not free text. Engineers can group drift, ingress and insulation failures by element lot, potting batch and housing supplier, then compare the stored coefficients with the returned reading.

Can calibration stations send files in directly?

Yes, as imported or attached files. The station software keeps working as before, and its output file is filed against the serial number.

How is a certificate wording changed?

Layouts are set during implementation with your quality staff, including wording, units and the signature block. Later changes to wording or fields are made by GullySystem staff on request.

What should we bring to the first session?

Bring one model code, a recent certificate and a sample of your calibration log. We use them to show the record running from element receipt to shipment.

What can we export?

Serial history, readings, coefficients, lots and orders can be exported as spreadsheets. Both sides sign off the column list and the way files are passed over before any export is run.

Wondering what it would cost? Share your requirements and an engineer will come back with a scope.

Industries

Businesses that use this.

Sensor manufacturers

Related products.

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